Wire Harness Installation Instructions 2019-11-14آ  7 harness kits are designed to mount the computer

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    Wire Harness Installation Instructions

    For Installing Harness Numbers:

    60211: 1996-2000 GM Vortec 7.4L Big Block V8 Harness

    Manual P/N 90541

    Painless Performance Products recommends you, the installer, read this installation manual from front to back before installing this harness.

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    Painless Performance Products, LLC

    2501 Ludelle St.

    Fort Worth, TX 76105-1036

    PHONE: 800-423-9696 FAX: 817-244-4024

    EMAIL: support@painlessperformance.com

    If you have any questions concerning the installation of this harness, feel free to call Painless Performance Products' Tech Line at 1-800-423- 9696. The Tech Line can be reached from 8 A.M. to 5 P.M. central time, Monday through Thursday, and 8 A.M. to 4:30 P.M. on Fridays.

    We have attempted to provide you with as accurate of instructions as

    possible and are always concerned about corrections or improvements that can be made. If you have found any issues or omissions, or simply have comments or suggestions concerning these instructions, please write us at the above address, send us a fax at (817) 244-4024, or email us at support@painlessperformance.com. We sincerely appreciate your business.

    Painless Performance Products, LLC shall in no event be liable in

    contract or tort (including negligence) for special, indirect, incidental, or consequential damages, such as but not limited to, loss of property damage, or any other damages, costs or expenses which might be claimed as the result of the use or failure of the goods sold hereby, except only the cost of repair or replacement.

    2nd Edition: November 2019

    Copyright © 2019 by Painless Performance Products, LLC

    CAUTION: BEFORE THE REMOVAL OF YOUR ORIGINAL

    HARNESS AND/OR THE INSTALL OF YOUR NEW PAINLESS HARNESS, DISCONNECT THE POWER FROM YOUR VEHICLE BY REMOVING THE NEGATIVE OR POSITIVE BATTERY CABLE FROM THE BATTERY.

    mailto:painless@painlessperformance.com mailto:painless@painlessperformance.com

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    TABLE OF CONTENTS PAGE # SECTION

    5 1. INTRODUCTION

    5 2. ABOUT THESE INSTRUCTIONS

    6 3. TOOLS NEEDED

    6 4. PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES

    6 4.1 TRANSMISSION FUNCTION

    6 4.2 GET TO KNOW THE ENGINE THAT YOU ARE USING

    7 5. GENERAL INSTALLATION INSTRUCTIONS

    8 5.1 GROUNDING THE VEHICLE

    8 5.2 ROUGH INSTALLATION

    8 5.3 HARNESS ATTACHMENT

    9 5.4 TERMINAL INSTALLATION INSTRUCTIONS

    10 6. INSTALLATION

    10 6.1 KIT CONTENTS

    10 6.2 SPECIFIC CIRCUIT CONNECTIONS

    12 6.3 ENGINE GROUP INSTALLATION

    16 6.4 TAIL SECTION INSTALLATION

    17 7. TROUBLE-SHOOTING INSTRUCTIONS

    17 7.1 THE "CHECK ENGINE" LIGHT

    17 7.2 RETRIEVING TROUBLE CODES FROM THE COMPUTER

    18 7.3 TROUBLE SHOOTING GUIDE FOR YOUR PAINLESS

    PERFORMANCE HARNESS

    19 7.4 WHEN TO CALL PAINLESS WIRING TECH LINE

    19 LIMITED WARRANTY AND RETURN POLICY

    LIST OF FIGURES PAGE # SECTION FIG. #

    10 KIT CONTENTS 6.1

    11 BRAKE SWITCH CONNCTION 6.2

    11 BRAKE SWITCH RELAY 6.3

    12 FUEL PUMP RELAY CONNECTOR 6.4

    13 KNOCK SENSOR CONNECTOR 6.5

    14 OXYGEN SENSOR 6.6

    14 MAP SENSOR 6.7

    14 CAM SENSOR (DIST.) 6.8

    14 CPS SENSOR 6.9

    14 INJECTORS 1 – 8 6.10

    14 COIL DRIVER 6.11

    15 TPS SENSOR & IAC VALVE 6.12

    15 IGNITION COIL 6.13

    15 MAF SENSOR 6.14

    15 ECT SENSOR 6.15

    15 IAT SENSOR 6.16

    15 FUEL PUMP/OIL PRESSURE SWITCH 6.17

    Continued…

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    LIST OF FIGURES PAGE # SECTION FIG. #

    16 A/T INPUT SPEED & VSS SENSOR,

    TRANSMISSION CONNECTION (4L80E) 6.18

    LIST OF TABLES PAGE # SECTION TABLE #

    7 COMPATIBLE PARTS 4.1

    12 DASH SECTION CONNECTIONS 6.1

    13 ENGINE SECTION CONNECTIONS 6.2

    13 INJECTOR WIRE COLORS 6.3

    16 TAIL SECTION CONNECTIONS 6.4

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    1. INTRODUCTION

    You have purchased what we at Painless Performance Products believe to be the most up-to-date and easiest-to-install automotive fuel injection harness on the market. It is designed for easy installation, even if you have no electrical experience.

    This harness is designed to be a complete wiring system for the fuel injection system on General Motors 1996-2000 7.4 engines. Also, to control the 4L80E automatic transmission using the 1996-1997 computer Service #16229684 and #16244210. This includes all wiring that is needed by the computer to run and control the injection system and transmission. This harness will get the Vortec engine and transmission up and operating but it is recommended that you also have the computer reprogrammed to remove anything in the original factory programming that relates to a device or devices that are not being used in your particular vehicle.

    NOTE: Most likely the check engine light will come on and stay on when using a computer with the original factory programming this is normal and is why we recommended that the computer be reprogrammed.

    NOTE: Most remanufactured computers come without any programming in them and must be programmed before they can be used.

    NOTE: The program in your computer must match the transmission that you plan on using. The 60211, require the use of a 4L80E transmission. If any other electronic transmission is used, a stand-alone control system is required.

    Usually, the computer, relays and fuse block can easily be mounted under the dash. Most of the wiring in the harness has been pre-terminated to the proper connector and all wire has been GM color-coded. All wiring is TXL, 600 volt, and 125 degree centigrade with cross-link insulation.

    This fuel injection system harness has been divided into three major groups:

    ENGINE GROUP Includes wiring for the fuel injectors, ignition system, and sensors.

    DASH GROUP Includes ignition feed wire, assembly line diagnostic link (DLC) connector, check engine light, computer connectors, brake switch wiring, tachometer wiring, VSS Signal wire, fuse block, and fuel pump relay connector.

    TAIL GROUP Include VSS wiring, transmission wiring and power wire for fuel pump.

    2. ABOUT THESE INSTRUCTIONS

    These instructions provide information for the installation of the 60211 Vortec Fuel Injection Harness Kit. The contents of these instructions are divided into major Sections, as follows:

    1.0 INTRODUCTION 2.0 ABOUT THESE INSTRUCTIONS 3.0 TOOLS NEEDED 4.0 PRE-INSTALLATION AND HARNESS ROUTING GUIDELINES 5.0 GENERAL INSTALLATION INSTRUCTIONS 6.0 60211 VORTEC FUEL INJECTION HARNESS KIT 7.0 TROUBLE-SHOOTING INSTRUCTIONS AND TROUBLE CODES

    Sections are further divided into Paragraphs and Steps. Throughout, the Figure numbers refer to illustration and the Table numbers refer to information in table form. These are located in or near the sections or paragraphs to which they correspond. Always pay careful attention to any notes or any text labeled CAUTION.

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    3. TOOLS NEEDED

    In addition to your regular tools, you will need, at least, the following:

    • Crimping tool NOTE: USE A QUALITY TOOL TO AVOID OVER-CRIMPING.

    • Wire stripper

    • Continuity teste CAUTION: DO NOT USE A TEST LIGHT TO TEST THE COMPUTER OR SENSOR WIRING OR YOU WILL DAMAGE THE COMPUTER.

    • Electric drill

    • 1 5/8" Hole saw FOR THE RUBBER GROMMET IN THE FIREWALL.

    4. PRE-INSTALLATION AND HARNESS

    ROUTING GUIDELINES

    The installation of your harness kit will consist of two parts:

    • The physical routing, positioning, and securing of the harness, wire groups, and individual wires and connectors.

    • The proper electrical connection of the individual circuits.

    We cannot tell you how to route the harness in your automobile. That depends a great deal upon the particular make of the automobile and what extent you want to secure and conceal the harness. We do offer some general guidelines and routing practices starting in Paragraph 5.3, general installation instructions in Section 5.0, and precise instruction concerning the electrical connections you will have to make beginning in Section 6.0. To help you begin thinking through the installation of your wire harness, read the following sections:

    4.1 TRANSMISSION FUNCTION

    If you are using the 4L80E transmission, you must use the vehicle speed sensor (VSS), and the correct brake switch. These are necessary to make the transmission work correctly. The vehicle speed sensor lets the computer know how fast the wheels are turning. The brake switch should be closed (electrically connected) when the brakes ARE NOT being applied and open (not electrically connected) when the brakes ARE being applied. This is the opposite of a standard brake light switch. If you are using a pressure brake switch, a SPDT relay must be installed to unlock the converter when the brakes are applied. See Figure 6.3

    4.2 GET TO KNOW THE PARTICULAR ENGINE YOU ARE USING:

    NOTE: The 96 – 00 7.4 had four oxygen sensors from the factory, but the harness has provisions for only two, one on the driver side and one on the passenger side of the engine. We removed the rear oxygen sensors since they originally were behind the catalytic converters and most pe